Poland's Transition to a Market Economy Prospects for Energy Efficiency and Conservation (1994) / Chapter Skim
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PART III: INDUSTRIAL ENERGY EFFICIENCY MANAGEMENT
PART III: INDUSTRIAL ENERGY EFFICIENCY MANAGEMENT
Pages 71-116
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From page 73... ...
of production processes, insufficient utilization of waste energy, incorrect exploitation of production and consumption installations, excessive fraction of energy-consuming products in the industrial production and export profile, insufficient utilization of secondary raw materials obtained from used products, and low efficiency of energy consumers (cars, refrigerators, buildings)
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From page 74... ...
For example, the fuel energy economy due to recuperation is 3-4 times greater than the amount of heat transferred in the recuperator. The external utilization of waste energy is more difficult, because the differences between the supply and demand cause a temporary surplus or deficit of the utilized energy.
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From page 75... ...
Hence undesirable ecological effects resulting from the fabrication ot a particular product appear not only in the last step of the production process, but also in the preceding steps, especially those producing energy carriers (production of electricity, heat, secondary fuels)
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From page 76... ...
Also, the long-ctistance transmission of heat recovered from combustion gases can be realizer! by means of an intermediate heat carrier, e.g.
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From page 77... ...
In Japanese steel plants the excessive steam from wasteheat boilers is utilizer! in a central power plant for electricity production.
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From page 78... ...
Expansion turbines for blast furnace gas An elevated pressure inside the blast furnace warrants the increased capacity of the process, but throttling of blast furnace gas implies an unnecessary energy loss. Also, in a Polish steel plant an elevated pressure occurs in blast furnaces, but expansion turbines have not yet been introducecl.
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From page 79... ...
It should be stressed that the problem of energy conservation should have priority over installation of pollution control equipment at energy conversion plants because the reduction of energy use is always accompanies! by reclucecI emission of pollution.
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From page 80... ...
. Szargut I., Zientek A.: Optimization of the waste-gas jet chamber and recuperator for the continuous heating furnace.
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From page 81... ...
I Recuperator with forced draft and recirculation of combustion gases Recuperator 11 Rec~t" it_ Fuel _ _ _ 7 r ~ ~ r - ' 6 3 1 l Conbushan pace 1 ~ 1 ~1~ blah furece d~arnber Jet cleanser n n n n n n n n n n n n r 1< ~+ I Fig.
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From page 83... ...
This paper presents the structure of the consumption of energy carriers within the whole chemical industry as well as in a few of the largest chemical factories which produce nitrogen fertilizers and organic products. These factories are among the fifteen largest energy consumers in Poland.
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From page 84... ...
The consumption of the most important energy carriers in this industry is shown below: natural gas coal · electnclty other below: 52.9% 3o.4o/o 1 1.3% 3 .4o/o The largest chemical factories and their energy consumption figures for 1990 are listed Zaklady Azotowe PULAWY Zaklady Azotowe KEDZlERZYN Zaklady Azotowe TARNOW Zaklady Azotowe WFOCLAWEK Zaklady Chemiczne OSWlECIM 40,010 T;J 26,045 T] 25,313 TJ 1 8,937 TJ 16,827 TJ Total energy consumption in those factories makes up about 40% of the whole chemical industry.
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From page 85... ...
in Zaklady Azotowe WhOCLAWEK, utilization of hydrogen from a chlorine plant for ammonia production will save of about ~ 1.500.000 ma of natural gas. Zaklady Chemiczne OSWlECIM will improve energy management by retrofitting their steam boilers, as well as saving on energy in the manufacture of organic products.
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From page 86... ...
Limitations of electricity production in condensing modules caused by excess grid electricity have resulted in reduction of local environmental problems. Fuel conversion efficiency obtainable in thermal power station reaches about 78 %.
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From page 87... ...
recently installed boilers, so that boiler replacement is not economically reasonable, availability of space for a relatively large desuiphurization plant, availability of spent chemicals to be utilized as absorbing agents. Another possibility for further development which must also be taken into consideration is the substitution of coal fuel with natural gas by using gas-f~red steam boilers or boiler systems cooperating with gas turbines.
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From page 88... ...
It can be seen that the Polish chemical industry faces substantial energy management problems which require significant contributions of modern technology and capital. Projects involving modernization of production processes are presented based on the specific examples of nitrogen fertilizer units.
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From page 89... ...
Figure ~ RANKING OF EN 60 50 40 P e r c e n t 30 20 10 o ROY CONSUMERS IN I NDUSTRY (1 990) Total energy consumption 2470 PJ 48 15 13 - 18 6 FUEL METALLURGICAL CHEMICAL MINERAL OTHER BRANCH OF INDUSTRY 89
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From page 90... ...
Figure 2 50 40 30 P e r c e n t 20 10 o STRUCTURE OF ENERGY CONSUMPTION IN THE CHEMICAL INDUSTRY Total energy consumption 324 PJ 46.3 COAL NATURAL GAS ELECTRICITY ENERGY CARRIERS 33.3 12.3 3.7 4.4 FUEL OIL OTHER 90
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From page 91... ...
Figure 3 100 80 P e r c e n t 60 40 20 o ENERGY CONSUMPTION IN BRANCHES OF THE CHEMICAL INDUSTRY Total energy consumption 324 PJ TOTAL FERTELIZERS ORGANIC COAL SULFUR MINING SYNT.FI BRES 91 NAT: GAS ELECTRICITY INORGANIC _ OTHER
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From page 92... ...
Figure 4 RANKING OF MAJOR ENERGY CONSUMERS IN CHEMICAL INDUSTRY 50 40 Energy Consumption (Thousand TJ)
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From page 93... ...
Figure 5 STRUCTURE OF INSTALLED THERMAL POWER IN CHEMICAL INDUSTRY Total: 12,500 MW - 450 Boilers Electuc-~86%) 93 Other-( 14%)
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From page 94... ...
Figure 6 6 5 4 3 Thermal Capacity (Thousand MW) 2 1 o Structure of Boiler's Age Total 12.500 MW- 450 boilers 6000 5750 750 up to 20 Y 94 20 - 40 Y over 40 Y
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From page 95... ...
Some moclern retrofit problems of steam turbines are illustrated in this paper. The attention is focused on retrofit measures through the increase of the turbine efficiency as well as through the increase of turbine durability.
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From page 96... ...
to increase the design methods' reliability and to perform their validation just to mention efficient application of the mathematical statistical methods to analyze standard test results of turbines and heat circuits, and 21 to recognize and control undesirable flow phenomena taking place at full and partial Toad of a turbine. The origins of current interest in modernization projects can be also seen in the observed trend of rising power system capacity and increasing contribution brought by nuclear plants being accompanied by a move from the basic to bus-peak operation of turbines originally designed for basic power generation.
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From page 97... ...
OPTION B I: (for Tow pressures in the condenser) with shortened rotor blades of the second and third stage, without damping wires in these stages, without stellite protection in stage three, and with new or modernized nozzle vanes of all the stages in the LP section.
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From page 98... ...
rotor blade of the third stage instead of the Baumann stage, with new nozzle blades of the third and fourht stages, and possibly with new nozzle blades of the first and second stages. All of these options are characterized by different features and application scopes.
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From page 99... ...
There exists nowadays a general opinion that "strong" erosion of rotor blades' leading edges in the last stage justifies their replacement or an expensive repair. The present state of development of blade erosion prediction techniques allows one to conclude that the effect exerted on the change of kinetostatic stresses in the blades, the change of blade vibration eigenfrequency, and the loss of efficiency by erosion of the rotor blades' leading edges is of much less significance than has been generally supposed.
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From page 100... ...
net 8 , _ ~1 B2 ~ _-1 1 I Original design __ _ 1 _ _ 100 _I_ _ _ . 3: fonsequences of the retrofit measures fig.
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From page 101... ...
a. Hj hoz/enice Power Station, Turbine 131<215,BlocknrB ill,/ Videos.
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From page 102... ...
. q energy conversion etic/ency of the L- P port of the turbine Fig.5 Modification of the shcxpe of the casing .
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From page 105... ...
1. INDUSTRIAL ENERGY CONSERVATION PROGRAMS IN PERSPECTIVE The good news is that there has been a drop in the developed world's energy use per unit of manufactured product of ~ to 3% per year for the last several decades.
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From page 106... ...
Industrial energy conservation programsfocus primarily on choosingfrom avai;labile technology options. Efficiency improvement is driven by two distinct forces: technological progress, which is the long-term trend, ant!
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From page 107... ...
1, substantial gains in energy efficiency were made during the 1950s and 1960s with energy prices flat and in some cases falling. Figure 1 follows a key commodity, ethylene, and tracks the energy efficiency of new plants offered by The Lummus Company, an engineering contractor (5~.
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From page 108... ...
985. When energy prices rise, as currently is happening when the former Eastern Bloc countries move to a market economy, this pattern repeats.
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From page 109... ...
Much of this technology was latent from the prior decades of low energy prices, but some was fresh and developed as a result of new tools like Tow-cost computer simulation of processes. Equipment suppliers also saw energy efficiency as the battleground and responded.
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From page 110... ...
2. Energy Conservation in the Process Industries, W
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From page 111... ...
18 12 10 2 Ethylene from Ethane - a thermodynamic success story {Thousand Blu}/(Pound EthyIene : thermodynamic requirement \ oL'll ,ililililill ,ilililililil Ililil 1966 1960 1986 1970 1976 1980 1986 1990 Fig. ~ Ethylene plant competition has traditionally been fought by the engineering contractors in the area of low energy per pound of ethylene.
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From page 112... ...
The shape of this curve depends on the ratio of energy costs to capital costs. For piping the ratio is extremely low (about 1 to 7~.
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From page 113... ...
technology, in my view, will be the fuel to drive the engine of a sustainable energy future, and (2) electricity will play an increasingly important role in meeting total energy needs in a manner most compatible with protecting the global environment.
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From page 114... ...
As older existing power plants face stringent new emission limits, which otherwise might have causer! their retirement, EPRI research is helping to provide repowering options, retrofit emission controls, and methods to assist utilities in converting to compliance fuels.
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From page 115... ...
This program is founded on the development of solid state, power electronic components to replace much slower acting mechanical devices, and the accompanying high speed and more comprehensive communication and controls will permit higher power flows on existing transmission lines and rights of way. Many of the concepts will also be applicable to the Tower voltage distribution systems.
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From page 116... ...
5. CONCLUSIONS I conclude by emphasizing that energy efficiency and productivity are themes so encompassing and pervasive that they will continue to have a profound impact on virtually every aspect of energy technology and on EPRI research.
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